Space station architecture, module, berthing hub, shell assembly, berthing mechanism and utility connection channel

ABSTRACT

A space station (20) includes a plurality of modules (24) and berthing hubs (22), joined by interconnections (26) which are sideways connectable. The modules (24) and hubs (22) are fastened together in a triangular configuration in three dimensions. The interconnections (26) include a pair of opposed, axially aligned, flanged ports (50) and a clamp latch (52) formed from a plurality of sections (54, 56 and 58) hinged along their length and extending circumferentially around the flanged ports (50). A hermetic seal (63) is formed between the ports (50). A utilities connection channel (68) extends between the ports (50). The channel (68) has a shell (70) with utilities connectors (74) movable between an extended position to mating connectors in the modules (24) and a withdrawn position. Assembly sequence and common module shell structure is detailed.

ORIGIN OF THE INVENTION

The invention described herein was made by an employee of the U.S.Government and may be manufactured and used by or for the Government forgovernmental purposes without the payment of any royalties thereon ortherefor.

This is a division of application Ser. No. 588,036 filed Nov. 9, 1984now U.S. Pat. No. 4,728,060.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This application relates to a novel form of a space station. Moreparticularly, it relates to a geometric form in which modules areinterconnected and to the assemblies for connecting controlledatmosphere modules to form a structure connected together in an improvedgeometrical configuration using an improved interconnection assembly andutility channel connection.

2. Description of the Prior Art

A variety of space station configurations is known in the prior art.However, a characteristic which tends to prevail in prior art spacestation designs is that they tend to import gravity bound geometricconventions to a gravity free atmosphere. Examples of prior art spacestation designs are disclosed in the following U.S. Patents: 3,144,219,issued Aug. 11, 1964 to Schnitzer; 3,169,725, issued Feb. 16, 1965 toBerglund; 3,300,162, issued Jan. 24, 1967 to Maynard et al.; 3,332,640,issued July 25, 1967 to Nesheim; 3,348,352, issued Oct. 24, 1967 toCummings; 3,478,986, issued Nov. 18, 1969 to Fogarty; 3,744,739, issuedJuly 10, 1973 to Weaver et al.; 4,057,207, issued Nov. 8, 1977 to Hogan;4,299,066, issued Nov. 10, 1981 to Thompson; 4,308,699, issued Jan. 5,1982 to Slysh; and 4,377,266, issued Mar. 22, 1983 to Belew et al. Whilethese patents show that the art of space station construction is a welldeveloped one, a need remains for further improvements in suchconstruction, in order to improve safety, ease and versatility ofhandling and interconnection, and interconnection of utilities amongmodular units making up a space station or other controlled atmosphereenvironment.

SUMMARY OF THE INVENTION

Accordingly, it is an object of this invention to provide a spacestation that is deployable as space shuttle cargo in stages.

It is another object of the invention to provide a construction form fora space station or other controlled atmosphere environment which willprovide a maximum efficiency connectivity and packing density ofcontrolled atmosphere modules making up the space station or otherenvironment.

It is a further object of the invention to provide a laterallyapproachable berthing mechanism for modular assembly of a space station.

It is yet another object of the invention to provide an improved form ofutilities hookup for connecting modules in a modular controlledatmosphere construction.

It is another object of the invention to provide an omnidirectionallysymmetrical space station berthing hub with a reverse angle cone ofapproach for docking or other interconnection.

It is a further object of the invention to provide a space stationstructure in which modules making up the space station have their centerof gravity controllable in close proximity to their center of shapesymmetry.

It is another object of the invention to provide a space station orother controlled atmosphere environment employing a standardized shellstructure using hemispherical end caps for modules and to form sphericalhubs.

It is yet another object of the invention to provide a modular spacestation assembly in which utilities connections can be made in ashirtsleeves environment that allows fine finger manipulation of utilityconnectors.

The attainment of the foregoing and related objects may be achievedthrough use of the novel space station architecture, interconnectionassembly, berthing hub and utilities connection channel hereindisclosed. A space station architecture in accordance with thisinvention has a controlled atmosphere environment with a plurality ofinterconnected modules having opposed connection ports with activemechanisms which are sideways connectable to a passive port of aberthing hub. The modules are desirably interconnected in a triangularconfiguration in two dimensions and a tetrahedral configuration in threedimensions. The result is a fully packed, symmetrical, self-rigidizingstructure with a center of gravity in close proximity to its center ofshape symmetry.

In another aspect of the invention, a spherical, polyhedral, orspherical derivative hub is used for docking and for moduleinterconnection. The docking hub has a reverse angle cone of approachwhen employed for docking purposes. It also includes a maximum of 14berthing ports all at 60 degrees face angles from each other.

In a further aspect of the invention, the hub incorporates a utilitiesconnector channel which distributes gases, electric powercommunications, data links, control circuits, water and other fluidsthroughout the interconnected modules and docked transport ship in animproved manner through use of extendable opposing conduits adapted tointerlock with mating sockets imbedded in the modules and hub pressureshells.

Because the triangulated structure is self-rigidizing, without requiringresistance to bending movements or torques at the hubs, the hubs neednot be designed to resist bending or torques. This geometrical advantagewill allow significant reduction in structural weight and depth. Becauseit is not necessary to resist bending and torques in thisnon-rectangular structure, it is possible to provide noise and vibrationisolation between modules, which is very difficult, if not impossible incartesian coordinate/rectangular configurations.

Further, the triangular/tetrahedral station has specific flight attitudeand controllability properties. The triangular, two-dimensional planarstation has advantages in terms of minimal atmospheric drag, equalizedaerotorques with the center of pressure aligned with the center ofgravity. It has the ability to fly in an earth-inertial, gravitygradient mode where the long axis through the center of the mass willpoint towards the center of the earth as a natural flight attitude. Thisflight attitude will allow the use of gravity gradient countertorques tocounterbalance the aerotorques acting on solar arrays used to power thestation.

The tetrahedral, three-dimensional station has other properties. Becauseit is self-rigidizing and omnidirectionally symmetrical, it can fly inan isotropic manner. That is, there is no natural preference for anyorientation, so that the entire station can be rotated or otherwisemaneuvered for orientation in any flight attitude, with minimumimbalance in its controllability. The atmospheric drag profile of thetetrahedral station is bigger than the triangular/planar station, but itcan fly in generally symmetrical modes that will allow equalization andcancellation of aerotorques.

The connectors allow easy manual access for maintenance, repair,modification and replacement of utility systems in a shirtsleevesenvironment.

The attainment of the foregoing and related objects, advantages andfeatures of the invention should be more readily apparent to thoseskilled in the art, after review of the following more detaileddescription of the invention, taken together with the drawings, inwhich:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tetrahedral space station inaccordance with the invention.

FIG. 2 is a longitudinal section view taken along the line 2--2 in FIG.2a of a berthing mechanism for assembling hubs and modules in accordancewith the invention.

FIG. 2a is a cross section view taken along the line 2a--2a in FIG. 2.

FIG. 3 is a longitudinal section view taken along the line 3--3 in FIG.3a of a portion of the assembly in FIG. 2, but in another stage ofassembly, with a structural clamp closed.

FIG. 3a is a cross section view taken along the line 3a--3a in FIG. 3.

FIG. 4 is a perspective view of the assembly shown in FIG. 3, but at thecompletion of assembly.

FIG. 5 is a perspective view of a utility connection channel inaccordance with the invention.

FIG. 6 is a cross section view of a portion of the utility connectionchannel for fluid and gas utilities shown in FIG. 5.

FIG. 7 is a cross section view of another portion of the utilityconnection channel for electrical utilities shown in FIG. 5.

FIG. 8 is an end view of the utility connection channel of FIG. 5.

FIG. 9 is a cross section view taken along the line 8--8 in FIG. 4 andshowing utility connection channels as in FIG. 5 in place in theassembly of FIG. 4.

FIG. 10 is a cross section view taken along the line 10--10 in FIG. 1,showing details of a spherical berthing hub in accordance with theinvention.

FIG. 11 is a side and partial cross section view showing transport in aspace shuttle cargo bay of space station components in accordance withthe invention.

FIGS. 12a through 12f are plan views showing sequential assembly of aspace station in accordance with the invention.

FIG. 13 is a side section and elevation view of a typical module and hubpair of another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, more particularly to FIGS. 1-4, there isshown a space station assembly 20 with berthing hubs 22 in accordancewith this invention. Modules 24 are assembled by the hubs 22 in atriangular configuration in two dimensions and a tetrahedralconfiguration in three dimensions, using a berthing mechanism 26, shownin FIGS. 2-4, to be described below. The cylindrical modules 24 may beoutfitted in their interior to serve a variety of different uses in thespace station, as indicated by the labels in FIG. 1. Other equipment andmodules may be attached to or incorporated into the space station 20,including logistics modules 28, a payload berthing or construction beam30, a power resources module 32, including solar cell panels 34, anddetachable experiment/laboratory module 36. As shown, one of the hubs 22is employed for berthing space shuttle 38, using the same linkageassembly 26 used to attach modules 24 and the other components of thespace station 20 together through the hubs 22, or the standardApollo-Soyuz type single vector port (for shuttle only). Because theshuttle berthing hub 22 is located on an outside of an acute corner 40of the tetrahedral configuration, the shuttle berthing hub 22 provides a"reverse" approach cone, making the berthing operation less difficultthan with a more confining approach cone to a straight or planarsurface.

The space station 20 of FIG. 1 is shown in the configuration of a singletetrahedron. However, larger space stations made up of multipletetrahedra comprised of hubs and modules assembled from modules 24interconnected through hubs 22 and with berthing mechanisms 26 may beconstructed. Significant advantages are obtained through use of such atetrahedral form of construction arising from the self stabilizing orrigidizing, space filling, and equal interior and exterior angleproperties of a tetrahedron. The space station 20, as well as largerspace stations incorporating many tetrahedrons, are structurally stableand are omnidirectionally symmetric. In particular, the omnidirectionalsymmetry means that a close correlation can be maintained between atriangular or tetrahedral space station's shape symmetry and center ofgravity. Such a close correlation is advantageous for orienting andmoving the space station with thrusters and similar means of propulsion.

FIGS. 2-4 show details of the berthing mechanism 26 of the space station20 in FIG. 1 at various stages in the process of assembly. Module 24 andhub 22 each have flanged ports 50, which mate together to form theprimary pressure seal 26. A clamp 52 consists of sections 54, 56 and 58,which are connected together by hinges 60 along their length. Radialstiffeners 61 are provided around the sections 54-58, for structuralstrength in the completed assembly. In the process of assembly, themodule 24 and hub 22 are moved laterally together to the position shownin FIG. 2, with the section 56 of the clamp 52 engaging both flangedports 50. With the structural axes of the flanged ports 50 aligned inthis manner, sections 54 and 58 of the clamp 52 are closed and latchedloosely to allow rotation but not separation, to give the configurationshown in FIG. 4. Module 24 is then rotated about the structural axis ofits flanged port 50 as necessary to align utilities connections withinthe assembly 26, to be described below. The clamp 52 is then tightenedand secured. A primary pressure seal 63 (FIG. 3) is made at the matingflanges 62, and the assembly 26 is then pressurized. Hatches 64 and 66in the hub 22 and the module 24 may now be opened by swinging ortranslating. Utilities channel connections 68 may now be inserted intothe berthing assembly 26 in a "shirtsleeves" environment to complete andconnection of module 24 and hub 22. This process of assembly is used tointerconnect all of the modules and hubs of the space station 20, andmay also be applied to docking with the space shuttle 38.

An example of a utilities connection channel 68 is shown in FIG. 5. Theconnection channel 68 has a shell 70 with a radius of curvatureconfigured to fit into the berthing assembly 26. Utility connector 72and electrical connectors 74 are mounted inside channel housing 70. Whenthe connection channel 68 is installed in the assembly 26, the utilityconnector 72 and the electrical connectors 74 are aligned oppositeutility aperture 77 and electrical apertures 78, respectively. Anactuator 80 on each end of the utility connector 72 is turned by anautomated mechanism or by hand to extend the utility connector 72 intoits corresponding utility aperture 77. Similar actuators 81 inside thechannel housing on each end of the electrical connectors 74 are turnedto extend the electrical connectors 74 into electrical apertures 78 inmodule 24 and hub 22.

Details of the gas or fluid utility connector 72 and the utilityaperture 77 are shown in FIG. 6. Tube 82 is fixedly mounted within thechannel housing 70 at fixed mount 76. Actuator 80 is in the form of adrive nut which is threaded to the utility tube 82. End 84 of theutility connector 72 is connected to the actuator drive nut 80 by meansof bearing 85, so that drive nut actuator 80 can rotate relative to theend 84. Fitting 86 into which the end 84 of connector 72 is extended byrotation of the drive nut actuator 80 is embedded in pressure shell wall87 of the hub 22 by means of locknut and washer 88 and flange 89.Gaskets 90 ensure a hermetic seal among the tube 82, end 84, fitting 86and wall 87. In use, the connection channel 68 is positioned so that end84 is opposite aperture 77, and a spanner or similar wrench is manuallyor automatically used to drive nut 80 to advance the connector tip 84into the utility aperture 77.

Details of the electrical connector 74 are shown in FIG. 7. As in thecase of the utility tube 82, the electrical cable 91 extends from thefixed mount 76 of the connection channel shell 70. A connector end 92 isthreaded to the cable 91. Male connector pins 94 are mounted throughblock 95 and are attached to wires 96 within cable 91.

Also as in the utility connector 72, electrical apertures 78 are formedin an imbed fitting 97 extending through pressure walls 87 of the hub22. Flange 98 and a locknut and washer 88 fix the imbed fitting 97 inplace. Female connection pins 99 extend through block 100 within theimbed fitting 97. Threaded end 101 extends within the electricalaperture 78 surrounding the female connection pins 99, and isdimensioned to receive the connector end 92. A guide ridge 102 withinthe end 101 assures proper orientation of the end 92 within end 101 formating of the male pins with the female pins 96. Nut tightener 81advances the end 92 within the end 101. Gaskets 90 provide a hermeticseal among walls 87, imbed fitting 97 and ends 92 and 101.

FIG. 8 shows additional details of the installation of the connectionchannels 68. Connection channels 68 are mounted in the inside surface ofpressure shells 103 of the berthing ports 50 by means of index andanchoring support tabs 105 and bolts 107. Openings 109 in end wall 109aof the port 50 allow some flexibility in the location of male electricalconnectors 74, female electrical apertures 78, male utility fluid or gasconnectors 72 and female utility apertures 77, all of which are providedeither in the mounts 76 of the connector channel 68 or in the hub 22 inmating relationship. Each connector channel 68 has a cover 111, hingedat 113 and latched at 115 to protect the utilities from adjacent throughtraffic and allow access to the interior of connection channel 68 formaintenance and installation. In practice, the connection channel 68 canbe fabricated from light gauge aluminum or other sheet metal.

FIG. 9 shows a layout of completed utilities connections in the berthingassembly 26. With the exception of the arc-segments of hatch hinge 117and hatch latch 119, the connector channels 68 are installed in theentire circumference of the linkage assembly 26. The connector channels68 can include a pneumatics channel 104, an intercom and video channel106, a computer data link channel 108, a thermal coolant channel 110,and an electrical power channel 112. Duplicates of these channels104-112 and other channels 68 are provided around the circumference ofthe assembly 26 as needed, in mirror image or inverted mirror imageconfiguration.

FIG. 10 shows further details of the hubs 22 in the space station 20.The flanged berthing ports 50 are spaced around the spherical orpolyhedral interior of the hub 22. A total of six (in the figure) suchports 50 are provided in the hub 22, although a greater or lesser numberof such ports can be provided for potential interconnections, with thelimiting number of ports being determined by spacing required for themodules or other space station ports to be connected to the hub 22.Utilities lines 114 extend within the hub 22 and are fed into each port50 for connection in a berthing assembly 26 incorporating the port 50.Utilities lines 114 extend between ports 50 in great circle arcs frominner collar 115 to inner collar 115. Person 116 passes through theports 50 and the hub 22 while passing from one module 24 to anothermodule 24 in the space station 20. Connection channels 68 extend betweenthe flanged ports 50 of adjacent hubs 22 and modules 24. The hub 22 isformed from double walls 121.

FIG. 11 shows how modules 24 and hubs 22 making up the space station 20may be raised into orbit using the space shuttle 38. The placement ofthe denser hub at the stern/bottom of the cargo bay will conserve thecritical location of the total shuttle cargo center of gravity envelope.A module 24 and a hub 22 may be interconnected on the ground andinserted in the cargo bay 118 of the shuttle 38. In this manner, aminimal configuration space station consisting of three modules 24,three hubs 22, and several smaller modules and other parts may be raisedinto orbit in four shuttle launches. FIG. 10 also shows a docking andairlock port 120 for docking the shuttle 38 to the space station 20, inthe same manner of interconnection assembly explained above for thespace station 20 itself, or using existing Apollo-Soyuz type dockingtechnology.

FIGS. 12a through 12f show an assembly sequence for a space station 150based on a two dimensional triangle form of construction, which showsthat a close correlation between axes of shape symmetry and centers ofgravity may be maintained for the space station 150 as it grows. Whenthe total mass of the space station is smaller, a more eccentricallylocated center of gravity can be allowed, but as the total massincreases, the center of gravity approaches closer to the symmetry ofthe station. In FIG. 12a, a logistics module 28 and a power resourcesmodule 32 are interconnected by hub 22. Center of gravity 200 of thisassembly is slightly to one side of axis of symmetry 154. In FIG. 12b, amodule 24 has been added to the assembly, along with a reboost module156 for repositioning the space station 150 in its orbit. Center ofgravity 200 of the space station 150 is slightly to one side of axis ofsymmetry 160 for the module 24. In FIG. 12c, a second module 24 has beenconnected to the hub 22, a second logistics rack 28 has been added andthe reboost module 156 in FIG. 12b has been relocated and a beam 30 hasbeen installed as a temporary construction brace for the modules 24. Inthis configuration, the center of gravity 200 and axis of shape symmetry154 almost coincide. In FIG. 12d, two more hubs 22 with logistics racks28 and reboost modules 156 have been added. Beam 30 now connects the twoadditional hubs 22. The center of gravity 200 of this assembly remainsalmost on the axis of shape symmetry 154. In FIG. 12e, a third module 24is connected between the second and third hubs 22, a second power module32 is installed on the third hub 22, and the beam 30 is stowed parallelto the third module 24. The center of gravity 200 of space station 150is now slightly to one side of the axis 154. The FIG. 12f, the firstpower module 22 has been relocated to the second hub 22, so that the twopower modules 32 are at opposite ends of the station 150. A fourth andfifth module 24 have been added, to form a new triangle in the station150. A fourth hub 22 has been added, and logistics racks 28 and reboostmodules 156 are included and relocated as required. Center of gravity200 and the cross-axes of shape symmetry 154 now coincide. Thisconfiguration allows ready reorientation and reboosting of the enlargedspace station 150. In a similar manner, the space station 150 may befurther enlarged in two or three dimensions by forming additionaltriangular assemblies of hubs 22 and modules 24.

FIG. 13 shows a portion of another embodiment of a space station 201 inaccordance with the invention; a typical module and berthing hub pair.The embodiment incorporates a berthing hub 22 as employed in the FIGS.1-12 embodiments. Module 202 incorporates a cylinder 204 withhemispherical or hemi-polyhedral end caps 204 and 206. The hemisphericalend caps 204 and 206 have flanged ports 50 of the same type as theflanged ports 50 of the spherical berthing hub 22. The module with itshemispherical end caps carries the active portion of the berthingmechanism, and the hub ports carry the passive portion. As shown, thehemispherical end caps 204 and 206 have a diameter somewhat less thanthe diameter of cylinder 203, for example, 12 feet for the end capdiameter and 14 feet for the cylinder diameter. In this embodiment, thediameter of end caps 204 and 206 is the same as the diameter of hub 22.A conical adapter section 208 at each end of the cylinder 203 joins thecylinder 203 to the hemispherical end caps 204 and 206. If desired, theend caps could have the same diameter as the cylinder 203 and bedirectly connected to it.

As shown, the hemispherical end cap 204 is configured as an air lock. Ifdesired, the on axis flanged port 50 of the end cap 204 may be connectedto another module, either directly, or through a berthing hub 22. Theother flanged port 50 is used for access to space.

In use of the air lock formed by hemispherical end cap 204, an ExtraVehicular Activity (EVA) suit ("space suit") 210 is stored near hatch212 connecting the end cap 204 and the cylinder 203. An astronaut orteam of astronauts puts on the space suit 210, enters the hemisphericalend cap 204, seals each hatch 212, 214 and 216, pumps down the end capairlock 204, and then exits from the space station 200 through the hatch216. This airlock can be sized to accommodate a larger team ofastronauts going out EVA than the current shuttle airlock whichaccommodates only two.

A different use is shown for the hemispherical end cap 206. The end cap206 serves to increase the available space in cylinder 203, as aconnector to the berthing hub 22 through one flanged port 50, and as aconnector through a second flanged port 50 to observation dome 214 formechanical arm remote manipulator system (RMS) 216, used to manipulateequipment outside the space station 200 from within the station.

As indicated in FIG. 13, the module 202 may be laid out to include avariety of functions, including a protected safe haven emergency supplypackage which, in the event of significant damage to the space station200, will support life for the crew independently in that module for aperiod of time (such as 30 days) until repairs or rescue can beeffected.

The hemispherical end caps 204 and 206 provide a number of advantagesfor the space station 200. Since the end caps 204 and 206 are based onthe same form factor as the hubs 22, common tooling can be used. The endcaps 204 and 206 can be used for a variety of purposes, thus increasingthe options available in the assembly of the space station 200. Hatch216 of the end cap 204 may be used as an alternative access to thecylinder 203 when the flanged port 50 of hatch 214 has already beenblocked off in the space shuttle 38 prior to launch. Such an alternativeaccess is highly convenient for last minute loading of, for example,life sciences experiments just prior to shuttle launch.

It should now be readily apparent to those skilled in the art that anovel space station, berthing mechanism assembly, berthing hubs andutility connection channels common module shell capable of achieving thestated objects of the invention has been provided. Through use of thetriangular and tetrahedral space station architecture of this invention,a space filling structure of modules may be arranged withomnidirectional symmetry. The sideways approachable coupling assemblyfacilitates both assembly of the space station and docking. Theconnection channel provides a convenient utilities feed through asmodules are added to the space station. Critical connection functionsare separated by a vector both in time and in space. The component partsof a space station in accordance with this invention may be raised intoorbit with a small number of space shuttle launches and assembled intothe completed space station easily. Such a space station may grow into alarge installation over time through the addition of additional modulesand couplings.

It should further be apparent to those skilled in the art that variouschanges in form and detail of the invention as shown and described maybe made. For example, the hub 22 and end caps 204 and 206 in FIG. 13could be polyhedral in configuration. It is intended that such changesbe included within the spirit and scope of the claims appended hereto.

What is claimed is:
 1. A fluid connector assembly comprising:first andsecond connecting members, said second connecting member being adaptedto receive varying portions of said first connecting member, means forcreating a hermetic seal between said first and second connectingmembers when they are engaged, said first connecting member having firstand second overlapping tubes that are movable longitudinally withrespect to each other, a hermetic seal between said first and secondtubes, and means attached to said tubes for moving said second tube toand fro with respect to said first tube and changing the amount ofengagement between said second tube and said second connecting member,said moving means including a threaded portion on the exterior of saidfirst tube, a nut with threads engaging the threaded portion of saidfirst tube, and means for rotatably coupling said nut to said secondtube.
 2. The connector assembly of claim 1 wherein said means forrotatably coupling said nut to said second tube comprises a bearingsituated at the end of said second tube remote from said secondconnecting member.
 3. The connector assembly of claim 1 wherein saidsecond connecting member includes a cylindrical fitting having an insidediameter slightly larger than the outer diameter of said second tube anda proximate end where the second tube of the first connecting member isinserted, said fitting having an exterior flange displaced from saidproximate end, a fastener for attaching to said proximate end wherebysaid fitting may be installed in a wall aperture with the wall portionadjacent said fitting situated between the flange and the fastener.